Syllabus [Structural Analyst Program] - Innovent€¦ · Syllabus [Structural Analyst Program] ......

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Syllabus [Structural Analyst Program] – Duration: 3 months [12 weeks]

Week 1 & 2: Simulation Tool Training

TOPIC CONTENT WORKSHOPS

FEA and ANSYS About ANSYS, What is FEA?, Instructor Example

Getting Started

Interactive Vs. Batch Mode, Starting ANSYS, Product Launcher, ANSYS Workbench, Memory, GUI, The Database and Files, Exiting ANSYS

1) Introductory Workshop

2) Getting Started Workshop

ANSYS Basics Overview, Plotting, Picking, Coordinate Systems, Select Logic, Components

3) ANSYS Basics Workshop

General Analysis Procedure

Preliminary Decisions, Preprocessing, Create Solid Model, Create FEA Model, Define Material, Solution, Postprocessing, Review Results, Verification



Creating the Solid Model

What to Model?, Importing Geometry, IGES Import, Connection Products, ANSYS Native Commands, Definitions, ANSYS Native Geometry Creation, Working Plane, ANSYS Coordinate Systems and Working Plane Coord. System

1) Importing Solid models- IGES,

SAT, SAT Assembly,

Parasolid, Parasolid Assembly

2) Pillow Block Modeling

3) Connecting Rod

4) Connecting Rod

Import/Cleanup

Creating the Finite Element Model

Overview, Element Attributes, Multiple Element Attributes, Controlling Mesh Density, Mesh Order Control, Generating the Mesh, Hex-to-Tex Meshing, Mesh Extrusion, Sweep Meshing, F.E. Imports

5) Silo

6) Pillow Block

7) Cotter Pin

8) Connecting Rod

9) Impeller Extrusion

10) Wheel



Defining the Material Units, ANSYS Defined Materials, Material Model GUI, Listing Defined Materials

1) User Input Material

Loading Define Loads, Nodal Coordinate Systems, Displacement Constraint, Concentrated Forces, Verifying Loads

Solution Solvers, Definitions, Multiple Loadsteps

2) 3D Bracket

3) Connecting Rod

4) Wheel

Structural Analysis Preprocessing, Solution, Postprocessing

5) Lathe Cutter

6) 2D Corner Bracket

Thermal Analysis Preprocessing, Solution, Postprocessing

7) Axisymmetric Pipe with Fins

Postprocessing

Query Picking, Results Coordinate System, Path Operation, Error Estimation, Load Case Combinations, Results Viewer, Variable Viewer, Report Generator

8) Connecting Rod

9) Spherical Shell

10) Axisymmetric Fin with

Multiple Load Steps



Array Parameters Types of Array Parameters, Retrieving Database Information, Array Operations

1) Axisymmetric Wheel

Coupling & Constraint Equations

Coupling, Constraint Equations

2) Impeller Blade (Coupling)

3) Turbine Blade (Constraint

Equation)

4) Swaybar (Rigid Regions)

Working with Elements Element Coordinate System, Surface Effect Elements, Element Table

5) Bolt Torque (Surface Effect Elements)

Beam Modeling Beam Properties, Beam meshing, Loading, Solution and Results

6) Building Frame

Couple Field Analysis Sequential method, direct method 7) Thermal Pipe



Submodeling General Procedure 1) Crank Shaft

Modal Analysis Procedure 2) U-Bracket

Introduction to Nonlinear Analysis

Basic Concepts, Typical Procedure 3) Arched Beam

Bonded Contact Definitions, Typical Procedure 4) Swaybar

Macro Basics

Open forum discussion

Creating a Macro, Macro with Arguments, Branching, Looping, General Guidelines

5) Verifying Pressures


Batch Allocation [Total 4 batches] – Sample Week [from week 3 to 10] Lecture and Practice Sessions

Self-learning Sessions

Day Contact Session

Practice session

Batch Day Work Definition

Day 1 Batch 1 Batch 3 Batch 1 3 & 6 CT* & SA**

Day 2 Batch 2 Batch 1





* Critical Thinking; **Self-assessment

* Critical thinking is an innovative method of learning instead of a traditional method. Herein we take an applied

situation which is real time and solve the same by systematic application of the concepts with out-of-the-box thinking. This gives a detailed understanding of the physics, but significantly improves problem solving skills.

Week 3: Mechanics

What does this session achieve?

The concept of loads and load path is critical to the structural design, which is systematically

understood, which helps to understand the loading of a component in a particular product. Friction

is extremely important in many applications and this session gives a comprehensive understanding

of the role of friction in critical areas such as fits and Joints. Further, concept of inertia is important

not just in rigid body dynamics but also in vibration and Rotordynamics. Thus, this session helps

conceive all possible loads, load path, friction and inertia relevant to real time components and also

via simulation of the same.

FORENOON: Critical Thinking Situations

TOPIC SITUATIONS

Mechanics – Free Body Diagram (FBD)

a) FBD of a Landing Gear

b) 2 mass accelerating system

c) Shaft and Bearing system

Mechanics – Friction and Inertia

a) Bolted Joint – Friction consumed during pre-torque

b) Interference Fit – Load carrying capacity

c) Equilibrium of a 2 mass system under external load

d) Computation of MOI for a given system


AFTERNOON: Simulation Situations

TOPIC SITUATIONS

Mechanics – Free Body Diagram (FBD)

a) Recapitulate Important Concepts of Simulation

b) Landing Gear Analysis & Practice

Mechanics - Friction

a) Analysis of Bolted Joint Assembly & Practice

b) Analysis of Interference Fit & Practice

Week 4: Mechanics & Solid Mechanics


Modern day machinery runs on high power and speed necessitating the need for appreciating these

systems comprehensively. This session focuses on idealized dynamics of system (CAR) and

subsystems (gear train) and moderate mathematical treatment.

The second part of the session focusses on material modelling. This focusses on the role of material

properties in the engineering applications. For example Poisson’s ratio could bring about failure of a

rotating bolted joint or joint of a pipe. From Stress-strain curve of a material lot of information could

be derived about mechanics of the material. Material modelling for simulation is also effectively

demonstrated.



TOPIC SITUATIONS

Mechanics – Dynamics

a) Rotating Rectangle (Bearing reactions)

b) Mass & Spring System

c) Negotiating a sine wave

d) Analysis of a Gear Train

Solid Mechanics – Material Models

a) Role of Poisson’s Ratio

b) Visco-elastic and Visco-plastic behaviour

c) Fracture Toughness and Plasticity at Crack Tips

d) Stress-Strain Curve


TOPIC SITUATIONS

Mechanics – Dynamics

a) Analysis of 2 mass system on an inclined plane

b) Analysis of a mass negotiating a sine wave

c) Stress analysis of a Spur Gear

Solid Mechanics – Material Models

a) Introduction to material models in the simulation tool

b) Bolted pressure vessel analysis

c) Linear fracture analysis of a plate


Week 5: Solid Mechanics


The stress measure is crucial, whether it is a simple static analysis or fatigue lifing, any inaccuracy or

wrong stress measure can make a lot of difference to the prediction of the ANALYST about the

structural health. Further the fundamental loads such as bending and torsion are emphasized

through several trickier situations. Simulation uses many real-time components to understand the

component vulnerabilities to the worst bending and torsional loads.


TOPIC SITUATIONS

Solid Mechanics – Stress & Strain

a) Limitations of Von Mises

b) Concept of large deflection

c) Stress dependence on Material

d) Stress & Strain for a typical composite plate

Solid Mechanics – Transformation, SFD & BMD

a) Transformation for a Composite Plate

b) BMD & SFD for a C-Beam

c) Torsional Stiffness of a Beam

d) BMD & SFD of an Aircraft Wing


TOPIC SITUATIONS

Solid Mechanics – Stress & Strain

a) Stress concentration of a Hollow Cylinder with a Hole

b) Large deflection analysis (Flexible gripper & Pneumatic Fingers)

c) Stress analysis of a Gear Box

Solid Mechanics – Transformation, SFD & BMD

a) Combined non proportional loading of an axial and torsional loads

b) Analysis of a C-Beam and a Bulk Head

c) Torsional Rigidity of a Solid & Hollow Cylinder

d) Analysis of an Aircraft Wing with various loads


Week 6: Solid Mechanics


The stiffness and strain energy are two more indices that are as important as stress. The stiffness

tells us about the structural elastic stability. The strain energy distribution is also a measure of how

the material is utilized or stressed. Modal strain energy is used to statically trim the components.

This session focusses on failure modes related to stiffness and application of strain energy to analyze

structures. Simulation considers good structures from aero domain to illustrate buckling analysis of

various types of components and analysis of stiffeners that enhance the component stiffness.


TOPIC SITUATIONS

Solid Mechanics – Stress & Stiffness for Basic Structures

a) Optimization of a Cantilever Beam

b) Consequence of using Short Bolts

c) Finding the Effective Stiffness of a Bearing System

d) Finding Deflection of a Curved Beam

e) Torsion of a Solid Elliptical Shaft

f) Why Shell is more Efficient than a Plate & Stress Discontinuity in a Pressure Vessel

Solid Mechanics – Buckling & Asymmetric Bending

a) C-Frame Buckling

b) Hat & T Stiffeners for a Shell

c) Limit Post Buckling

d) Finding the Neutral Axis of an L-Section & Max Stresses



TOPIC SITUATIONS

Solid Mechanics – Stress & Stiffness for Basic Structures

a) Design Optimization of a Truss

b) Analyzing the Effective Stiffness of a Bearing System

c) Analysis of a Curved Beam

d) Torsion of a Solid Elliptical Shaft

e) Comparison of Stress Level for a Shell & Plate of same weight

Solid Mechanics – Buckling & Asymmetric Bending

a) Eigen Buckling Analysis of a C-Frame

b) Eigen Buckling Analysis of a Plate with T & Hat Stiffners

c) Limit Post Buckling Analysis of a Beam

d) Bending analysis of a C, L & T Sections


Week 7: Vibration


One of the fundamental margins that is established for a component is vibration margin apart from

stress margin. Vibratory stress is perhaps the most difficult parameter to assess in a multiaxial

loading situation. Further the damping, say material damping is very difficult to measure. The

concept of resonance, use of Campbell diagram, effect of temperature, friction and other

parameters are theoretically understood and also via simulation.


TOPIC SITUATIONS

Vibration – Free Vibration

a) Quantifying Natural Frequency

b) 2 mass system with Springs

c) Torsional Vibration of 2 Discs

d) Vibration Margin for Steel or Titanium and use of Campbell Chart

Vibration – Damped Free Vibration

a) Material Damping & Limitations

b) Complex Eigen Values & Negative Damping

c) Gyroscopic Couple Calculation & Natural Frequency of a Overhung Rotor


TOPIC SITUATIONS

Vibration – Free Vibration

a) Vibration analysis of a two mass system with and without Springs

b) Nodal diameters of a cyclic symmetric disc with and without temperature load

c) Torsional Vibration of a 2 Disc system

d) Validating the Vibration Margin for a hollow shaft with stiffener


Vibration – Damped Free Vibration

a) Damping modeling and introduction to basic rotordynamics in simulation tool

b) Rotor Dynamic analysis of an overhung shaft with and without bearing flexibility

Week 8: Vibration


After a detailed exposure to free and forced vibration with damping, this session deals with

capturing dynamic stress via various methods or standard practices at various OEMs. Further

vibration measurement such as use of accelerometer is also given a detailed understanding. The

transient dynamics and hence the concept of numerical damping is also focused and compared with

physical damping. A few important factors that lead to bearing loading are also discussed. Simulation

considers several examples from building response to unbalance response of a shaft, to reinforce

vibration analysis.


TOPIC SITUATIONS

Vibration – Forced Vibration

a) Selection of an accelerometer, location and faithfulness

b) Bearing reactions due to an eccentric plate

c) Unbalanced response of a shaft with bearing springs

Vibration – Dynamic Stress and Vibration Isolation

a) Role of Numerical Damping

b) Dynamic stress in the presence stress concentration features

c) Analysis of a 3D Aero foil for Vibratory Stresses

d) Vibration Isolation of a Flexible Foundation



TOPIC SITUATIONS

Vibration – Forced Vibration

a) Plotting standard response curves for a harmonic analysis

b) Harmonic analysis of a two storey building

c) Response of a shaft due to unbalance

Vibration – Dynamic Stress and Vibration Isolation

a) Analysis of a Cylinder impacting a plank

b) Dynamic stress capturing of an aero foil via amplification factor method / Goodman diagram approach

Week 9: Design


Design is all about sizing components, optimally, hence build an assembly optimally against all

possible failure modes. The incidental requirement are to read the drawing carefully understand the

component interaction, load path and joints. The latest trend in engineering materials is also crucial

as industry wants to reduce every possible gram of weight without compromising on component and

structural integrity. The session walks candidates through several design exercises including real

time risk sessions. This gives a detailed idea about the design process that takes place in an industry.



TOPIC SITUATIONS

Design – Component Design

a) How do you design a shaft system?

b) Failure modes for a Gear

c) ASME Standards & Limitation

d) Risk review for a Bolted Joint

Design – Ideas on Bearing, Shafts, Gears & Engineering materials

a) Why Bearing Lifing is different from Shaft Lifing?

b) Single crystal materials, Ceramics & Metal Matrix Composites, Material Testing & Characterization

c) Drawing Reading


TOPIC SITUATIONS

Design – Component Design

a) Supervised Exercise – Design of Shaft – Stress, Vibration and Lifing

Design – Ideas on Bearing, Shafts, Gears & Engineering materials

a) Supervised Exercise – Dynamic stress analysis of a Blade-Disc assembly


Week 10: FEM


Many successful analyst’s in industry grip the commercial tool and engineering concepts well rather

than the mathematical concepts of FEM. However the applied FEM facts are sometimes crucial to

interpret results and appreciate the accuracy. The session focusses on some of the applied facts of

FEM that directly influence convergence and the output.

Critical Thinking Situations

TOPIC SITUATIONS

Simulation – FEM Facts

a) Designing a Shape Function & Properties of Stiffness Matrix

b) Stiffness Matrix for Shells & Plates with and without Transverse Shear

c) FEM Locking, error, convergence & Use of Quadra Point Elements

Week 11 & 12: Mock Interviews [150 select questions]

Component Academic Industry

Physics Fundamentals 10 20

Simulation 10 20

Applied FEM 30 0

Loads & Failures 10 20

Product Situations 0 30

Syllabus [Structural Analyst Program] - Innovent€¦ · Syllabus [Structural Analyst Program] ......

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